Device and method for feeding, clamping and processing, particularly for geometric welding of automobile welding components in a work station

ABSTRACT

The invention concerns a method and a device for feeding, clamping, and processing, particularly for geometric welding of automobile body components in a work station. The invention method consists of side-section clamping frames which, after receiving a body side section with the help of portal robots which travel along an elevated four-axle portal in the X-Y axis, are brought into the geometrical welding station, positioned at both sides of the body conveyer system for geometrical welding. The device is characterized in that a four-axle portal ( 2 ) is arranged above the geometrical welding station and along which four-axle portal ( 2 ), on each side of the body conveyer system ( 1 ), at least one portal robot ( 3 ), from which side-section clamping frames ( 9 ) are hung, can travel in the X-Y axis between a position for receiving the body side sections ( 8 ) and a position for clamping and welding the body. The four-axle portal ( 2 ) consists of rails ( 5 ) which are stationary and parallel or at right angles to the body conveyer system ( 1 ), one or more cross members ( 4 ) which can travel along the rails ( 5 ), one or more portal robots ( 3 ) which can travel in the longitudinal direction of the cross members ( 4 ), and side-section clamping frames ( 9 ) which are vertically movable and/or rotatably attached about a ventricle axis on the portal robot ( 3 ).

FIELD OF THE INVENTION

The invention relates to a method for feeding, clamping and processing,particularly for geometric welding of car body components in aprocessing station, where the underbody group of the car body, if any,is brought jointly with at least one front wall through a car bodyconveyor system into the station for geometric welding and exactlypositioned there, and with the car body side sections being laid into aside section clamping frame, positioned in the welding station, clampedwith the components to be welded, and where car body side sections,underbody group and, if any, roof sections are joined to a car bodystructure by the aid of welding robots arranged laterally and/or abovethe car body by way of geometric welding and subsequently weldedtogether completely, preferably in another welding station. Theinvention also relates to a device for feeding, clamping and processing,particularly for geometric welding of car body components in aprocessing station.

BACKGROUND OF THE INVENTION

From DE 2810 822 C2 and DE 32 30 455 C2 devices are known for welding ofloosely joined car bodies for motor vehicles. The devices have a weldingand a fixing place in which a transport track is located to transportthe car body. Side section carriers are movable from a standby positioninto a working position and back and mounted at each side of thetransport track by positioning devices pressable against the car bodyand having positioning arms adapted to the geometric shape of the carbody to be welded. At least one welding device is located laterally ofthe transport track and provided with a welding head. The welding headis adjustable to the car body.

The positioning devices of each side are arranged at side sectioncarriers which in a swivable arrangement are hung to rails running inthe transport direction of the car body and are configured as a rotaryaxle. The side section carriers act as side section clamping frames forthose car body side sections which have already before been looselyconnected with the underbody in a separate working cycle. To exchangethe side section carriers for a set of other side section carriers whosepositioning device is adjusted to the geometric shape of another carbody type, these side section carriers are moved along the rails in thecar body transport direction. For loose joining of a car body,particularly for mounting of car body side sections and for subsequentgeometric welding and, if required, for welding-out, independentstations are required which need much free space. Moreover, a changeoverfrom one car body type to another is relatively extensive.

From WO95/32886 a generic method and a device are known for feeding,clamping and processing of car body components in a processing stationwhere the components are clamped with one or several clamping frame(s)and where the clamping frames for the side section frames and the roofframes are handled and fed by one or more multipleaxle manipulator(2).By the aid of the manipulators, the clamping frames are supportedagainst each other, positioned and locked, thus forming a clamping framecasing surrounding the component parts at least at four sides. Theclamping frames are equipped with suitable positioning devices and forma self-carrying clamping frame casing which is preferably closed inannular or cubic form around the car body. It takes a great deal ofspace in a hall and geometric welding can not be started until the wholeclamping frame casing is closed.

SUMMARY AND OBJECTS OF THE INVENTION

It is the primary object of this invention to provide a generic methodand a device for execution of this method in which said problems do notoccur.

According to the invention, a method for feeding, clamping andprocessing, particularly for geometric welding of car body components ina processing station is provided. The underbody group of the car body,if any, is brought jointly with at least one front wall through a carbody conveyor system into the station for geometric welding and exactlypositioned there, with the car body side sections being laid into a sidesection clamping frame, positioned in the welding station, clamped withthe components to be welded. Car body side sections, underbody groupand, if any, roof sections are joined to a car body structure by the aidof welding robots arranged laterally and/or above the car body by way ofgeometric welding and subsequently welded together completely,preferably in another welding station. The side section clamping framesare brought into the geometric welding station by the aid of portalrobots movable in X/Y direction at an elevated four-axle portal,positioned at both sides of the car body and clamped with the componentsto be welded. The welding robots are mounted laterally beside the carbody conveyor system and are swung and/or moved towards the weldingspots.

According to the invention, a device for feeding, clamping andprocessing, particularly for geometric welding of car body components ina processing station is also provided. The device has a car bodyconveyor system for transportation and exact positioning of theunderbody group of the car body in the geometric welding station. Sidesection clamping frames for feeding of car body side sections, feederunits, if required, for the front and rear roof cross members areprovided. Clamping devices are provided for joining and clamping ofcomponents to be welded, particularly of car body side sections, andformed of welding robots located beside the car body conveyor system ina swivable or movable arrangement for geometric welding of joined andclamped components. The geometric welding station has a four-axle portalat which at each side of the car body conveyor system at least oneportal robot with side section clamping frames is movable in X and Ydirection between a position for clamping and welding of the car body.The four-axle portal includes stationary rails arranged in parallel orrectangularly to the car body conveyor system, one or more cross membersmovable on the stationary rails, one or more portal robots movable in alongitudinal direction of the cross members, and side section clampingframes affixed vertically at the portal robot in movable arrangementand/or rotatably around a vertical axle.

The geometric welding system in accordance with this invention is aflexible combination-type tool concept for geometric welding of motorvehicle bodies (underbody, side sections, roof cross members, and roofplate) which is of a modular structure. By use of an elevated four-axleportal at which portal robots travel in X and Y direction, numerous tooldeposits for side section clamping frames can be properly arranged inthe area of the four-axle portal in such a manner that these aredirectly accessible for a portal robot. The number of car body modelswhich can be welded by the system is preferably limited only by thenumber of car body side section tool deposits in the system, but can beextended flexibly.

The car body side sections laid manually and/or by a robot into the sidesection clamping frame can be positioned at both sides of the car bodyby one portal robot each which is adjustable in height and rotatablearound a vertical axle and, if required, the body side sections can beclamped by the aid of stationary positioning and clamping elements withthose parts to be welded. Subsequently, for geometric welding, thewelding robots located laterally beside the car body conveyor system,are swung towards the welding spot and/or moved appropriately. As aresult of the fact that the portal robots for the side section clampingframes hang at an elevated four-axle portal and are movable in X and Ydirection, the welding robots standing laterally on the ground floor canbe moved unrestrictedly for the welding process, and the whole space iswell accessible for all the maintenance and handling work.

The four-axle portal in accordance with this invention consists ofstationary rails arranged in parallel or rectangularly to the car bodyconveyor system, one or several cross members movable on these rails,one or more portal robot(s) movable in longitudinal direction on thecross members, and vertically fixed side section clamping frames beingmovable and/or rotatable around a vertical axle. The portal robots thusin principle can directly approach all the areas of the field framed bythe rails and cross members and effect a change of side section clampingframes at any spot or take-up the car body side members with the sidesection clamping frames.

In accordance with the invention, it has turned out to be favorable tohave a cross beam on each side of the car body conveyor system in caseof stationary rails running transversely to the car body conveyorsystem, with at least one portal robot being movable on said cross beamwithin the local area of the four-axle portal. Then it is possible forthe portal robots with their cross beams to approach the raw car bodysimultaneously from both sides. To effect a change in models, bothportal robots can then move to an appropriate clamping frame station totake-up new side member clamping frames there in order to take other carbody side sections to the next raw car body. To shorten cycle time,particularly in case of frequent model changes, a device calledmega-framing station turned out to be favorable. Here, the stationaryrails runs at left and in parallel beside the car body conveyor system.In principle, as many cross members as desired can be movable on thesestationary rails in consecutive mode in the pass-through direction ofraw car bodies. But here the special feature is that at least two portalrobots are movable on each cross member by the aid of which the left andright car body side section can be fed at the same time. Moreover,during this joining procedure, the portal robots on one or severalneighboring cross member(s) can be equipped simultaneously with new sidesection clamping frames and/or car body side sections. Thus it ismanageable to achieve an extremely short cycle time.

The side section clamping frames and, if required, the clamping framesfor the front and rear cross members, too, can be hung in floatingarrangement to the portal robot and/or feeder units by the aid offlexible offset elements as provided for under this invention anddispose of detachable connections to allow for supply media.

Some advantages of the system can be summarized in key words as follows:

modular structure;

unlimited choice of models and, respectively, high flexibility;

no multiple geometry;

good accessibility of robots;

simple assembly;

maintenance-friendly;

optimum changeover concept;

simple clamping frame station;

simple feed of component parts, particularly of side sections and roofcross members;

use of as many welding robots as desired; and

sufficient space for roof feeding.

The various features of novelty which characterize the invention arepointed out with particularity in the claims annexed to and forming apart of this disclosure. For a better understanding of the invention,its operating advantages and specific objects attained by its uses,reference is made to the accompanying drawings and descriptive matter inwhich a preferred embodiment of the invention is illustrated.

BRIEF DESCRIPTION OF THE DRAWINGS IN THE DRAWINGS:

FIG. 1 is a top view on a geometric welding station;

FIG. 2 is a front view as per Line Y of FIG. 1;

FIG. 3 is a section as per Line A—A of FIG. 1;

FIG. 4 is a detail Z relative to FIG. 2 and a view V relative to detailZ;

FIG. 5 is a view X relative to FIG. 1;

FIG. 6 is a perspective view of another execution style relative to FIG.1;

DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring to the drawings in particular, the understructure of a carbody, if required, is brought jointly with a front wall through a carbody conveyor system 1 into the frame welding station and positioned andclamped there. The car body side sections 8 are either laid manually orthrough an automatic feeder in the form of a robot 7 into the sidesection clamping frame 9 and brought by portal robot 3 which is movableon cross member 4 and rails 5 of the four-axle portal 2 into thegeometric welding station. The car body side sections 8 are positionedin the station by the aid of side section clamping frame 9, clamped toform a complete compound with the steel structure around the car body.Thus the geometry of the raw car bodies fabricated with this system isalways identical.

The front and rear roof cross beams 15 (hoops) are laid with one feederunit 20/21 each onto the car body side sections 8 and fixed at the sidesection clamping frame 9. In addition, it is possible for anotherclamping frame 16, loaded with roof plate 19, to be brought into theframe welding station, positioned and clamped. Welding of theunderstructure group with car body side sections 8 as well as welding ofroof cross members 15 with car body side sections 8 is accomplished bysix robots 18 mounted at the ground floor. At its underside, portalrobot 3 is equipped with a telescope 6 to lift and set down the sidesection clamping frame 9 into tool deposit 11 and, respectively, at thecar body. To take-up the car body side sections 8, clamping arms 10 arearranged at the side section clamping frame 9 at various levels,properly adapted to the contour of the car body side section. Once thecar body side section 8 has been positioned at the car body, the sidesection clamping frame 9 is fixed for geometric welding via lower andupper positioning and clamping elements 12, 13. Inside the tool deposit11, for example, there are three positions for the side section clampingframe 9. FIG. 3, in particular, shows the car body conveyor system 1including lifter as well as centering and clamping unit for theunderbody group. The side section clamping frame 9 hangs at the lowerpart of telescope 6 of portal robot 3 and additionally it is connectedto it via media coupling 22 and docking unit 23. The positioning andclamping elements 12 and 13 are affixed to stationary, verticalsupports. Shown in more details in the lower section of FIG. 4 by DetailZ of FIG. 2 is the docking system for the side section clamping frame 9with media coupling 22, docking unit 23 and flexible offset elements 24.The upper part of FIG. 4 additionally shows a View V relative to thelower part with a more detailed explanation of media coupling 22.

Finally, FIG. 5 in a Side View X relative to FIG. 1 shows thearrangement of a robot 7 arranged laterally and stationary on the groundfor feeding of a car body side section 8 to the side section clampingframe 9 from a piling unit located outside the four-axle portal 2.Alternatively, the car body side sections can also be laid manually byoperators into the side section clamping frame 9. Upon take-up of thecar body side section 8 by side section clamping frame 9, both parts canbe raised by the aid of a telescope 6, turned at the portal robot arounda vertical axle, if required, and then be moved through portal robot 3inside the four-axle portal 2 at will, e.g. past robot 18 or beyond itup to the underbody arranged on car body conveyor system 1. There, theclamping frame 9 as one can see from FIG. 3—is firmly positioned andclamped by means of positioning and clamping elements 12, 13 atstationary vertical supports which are located in the area upstream anddownstream of the car body. Once the car body side section 8 has beenclamped with the relative parts of the car body, robot 18 firmlyarranged on the ground can be moved for geometric welding between thetwo vertical supports, to which elements 12 and 13 are affixed, throughto the car body side section 8 to effect geometric welding. By way ofthe inventive device, positioning of side section clamping frame 9upstream of the car body and movement of robot 18 can be accomplishedsimultaneously or consecutively in short intervals without incurring thenecessity of having to move the underbody further on the car bodyconveyor system 1. To change a side section clamping frame 9, e.g. toallow for another vehicle model, portal robot 3 can be moved to a tooldeposit 11 which is also available in the area of the four-axle portal2. FIG. 2 moreover shows that the clamping frame 16 for the roof crossmember 15 can be actuated by a robot arranged on the ground beside thecar body conveyor system 1. FIG. 6 shows the so-called mega-framingstation. Here, the stationary rails 5 are arranged in parallel besidethe car body conveyor system 1. Located on the rails 5 are two crossmembers 4 movable independently of each other, each equipped with twoportal robots 3. The two car body side sections are simultaneouslyconnected with the raw car body by means of the two portal robots 3 ofone cross member 4. In all of the four comer areas of the four-axleportal 2, there is a tool deposit 11 (clamping frame station) for sidesection clamping frames 9 so that portal robots 3 located on the secondcross member 4 e.g. can take-up new side section clamping frames 9 inthe area of tool deposit 11 concurrently to the joining of a raw carbody. Loading of side section clamping frames 9 with new car bodycomponents 8 at a suitable place not shown here can also be accomplishedconcurrently to the joining procedure.

While a specific embodiment of the invention has been shown anddescribed in detail to illustrate the application of the principles ofthe invention, it will be understood that the invention may be embodiedotherwise without departing from such principles.

What is claimed is:
 1. A method for feeding, clamping and processing for geometric welding of car body components in a processing station, the method comprising the steps of: providing a car body conveyor system; providing a station for geometric welding with an elevated four-axle portal extending to each side of the conveyor system; bringing car body components, including at least one front wall or at least one front wall and an underbody component group, with the car body conveyor system into the station for geometric welding and exactly positioning the car body components at the station; clamping car body components to be welded; laying car body side sections in a side section clamping frame; providing a portal robot movable in X/Y directions at the elevated four-axle portal; bringing side section clamping frames into the geometric welding station with the portal robot to position the side section clamping frames at both sides of the car body components; clamping car body side sections with the components to be welded; and providing welding robots mounted laterally to the side of the car body conveyor system; swinging welding robots mounted laterally beside the car body conveyor system and/or moving the robots towards the welding spots; joining car body side sections to a car body structure by the aid of the welding robots arranged laterally and/or welding robots arranged above the car body by way of geometric welding; and subsequently welding the parts together completely.
 2. A method according to claim 1, further comprising bringing the underbody group of the car body jointly with the at least one front wall with the car body conveyor system into the station for geometric welding and exactly positioning these there and joining the underbody group and roof sections to the car body structure by the aid of the welding robots.
 3. A method according to claim 1, wherein the side section clamping frames are fixed prior to the welding procedure with the components to be welded using stationary positioning and clamping elements.
 4. A method according to claim 1, wherein, said step of subsequently welding the parts together completely occurs in another welding station.
 5. A method for feeding, clamping and processing car body components, the method comprising the steps of: providing a car body conveyor system; providing a station for geometric welding with an elevated four-axle portal extending to each side of the conveyor system; bringing car body components, including at least one front wall or the at least one front wall and an underbody component group, with the car body conveyor system into the station and exactly positioning the car body components at the station; clamping car body components to be welded; laying car body side sections in a side section clamping frame; providing a portal robot at the elevated four-axle portal, the portal robot being movable in orthogonal directions in a plane above the conveyor; bringing side section clamping frames into the geometric welding station with the portal robot to position the side section clamping frames at both sides of the car body components; clamping car body side sections with the components to be welded; providing welding robots mounted laterally to the side of the car body conveyor system; swinging welding robots mounted laterally beside the car body conveyor system and/or moving the robots towards the welding spots; joining car body side sections to a car body structure by the aid of the welding robots arranged laterally and/or welding robots arranged above the car body by way of geometric welding; and subsequently welding the parts together completely.
 6. A method according to claim 5, further comprising bringing the underbody group of the car body jointly with the at least one front wall with the car body conveyor system into the station for geometric welding and exactly positioning these there and joining the underbody group and roof sections to the car body structure by the aid of the welding robots.
 7. A method according to claim 5, wherein the side section clamping frames are fixed prior to the welding procedure with the components to be welded using stationary positioning and clamping elements.
 8. A method according to claim 5, wherein, said step of subsequently welding the parts together completely occurs in another welding station. 